operator’s manual - northern lights
TRANSCRIPT
OMPFor Models: MP445D, MP668D, MP445T, MP668T,
MP668QT, MP445H, MP668H, MP40C, MP55C,MP65C, MP80C, and MP99C
OPERATOR’S MANUAL
Marine Generators | Marine Diesel Engines | Land-Based Generators
Diesel engine exhaust and some of its constitu-ents are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
— CALIFORNIA —Proposition 65 Warning:
Northern Lights4420 14th Avenue N.W.Seattle, WA 98107Tel: (206) 789-3880Fax: (206) 782-5455
Copyright ©2002 Alaska Diesel Electric, Inc.All rights reserved. Northern Lights™, andthe Northern Lights logo are trademarks ofAlaska Diesel Electric, Inc.
Printed in U.S.A.PART NO.: OMP 06/02
OMP 06-02
Read this operator's manual thoroughly before starting to operate your equipment.This manual contains information you will need to run and service your new unit.
OPERATOR'S MANUAL#O-MP for Models
MP445D, MP668D, MP445T, MP668T, MP668QT, MP445H, MP668H, MP40C, MP55C, MP65C, MP80C, and MP99C
INTRODUCTION ....................................................2 Models Included .................................................2 Model Numbers ..................................................2 Serial Numbers ...................................................2
WARRANTY ............................................................3
SAFETY RULES .....................................................3
COMPONENT LOCATIONS MP445D ..............................................................4 MP445H ..............................................................5 MP668T ..............................................................6
ENGINE & GENERATOR CONTROL PANELS Series 1, 3 & 4 ..............................................7 - 8
OPERATING PROCEDURES Before Starting ....................................................9 Generator Sets .............................................9 - 10 Shutdown Procedures .........................................9 Break-In Period ................................................ 10
SERVICING SCHEDULE CHART .....................11
SERVICE RECORD ............................................ 12
SERVICING Lubrication - General ....................................... 13 Checking Oil .................................................... 13 Oil Changes ..................................................... 13 Changing Oil Filter .......................................... 13 Air Filter .......................................................... 13 Valve Clearances .............................................. 14 Fuels - General ......................................... 14 - 15 Fuel Filters ....................................................... 15 Bleeding the Fuel System ................................ 15
Injector Service ........................................ 16 - 17 Injection Pump ......................................... 17 - 19 Turbocharger .................................................... 20 Turbo Boost ..................................................... 20 Cooling System - General ................................ 20 Engine Coolant Specifi cations ................. 20 - 21 Cooling System Flushing ................................. 22 Heat Exchanger Cleaning ................................ 22 Cleaning Gear Oil Coolers ............................... 22 Zinc Electrodes ........................................ 22 - 23 Raw Water Pump ............................................. 23 Generator Ends ................................................ 23 Electrical System - General ............................. 23 Booster Batteries .............................................. 24 Battery Care ..................................................... 24 Winterizing / Out-of-Service ........................... 24
TROUBLESHOOTING Electrical .......................................................... 25 Engine ...................................................... 25 - 26
DATA SHEETS Unit Specifi cations ........................................... 27
HEAT EXCHANGER DRAWING .................................................................. 28
WIRING DIAGRAMS DC Electrical 12V .................................... 29 - 30 DC Electrical 24V .................................... 31 - 32 ON-BOARD SPARE PARTS .............................. 33
Proprietary InformationThis publication is the property of Alaska Diesel Electric, Inc.
It may not be reproduced in whole or in part without the written permission of Alaska Diesel Electric, Inc.© Alaska Diesel Electric, Inc. All rights reserved. Litho U.S.A. Publication number OMP 06/02
Table of Contents
1
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Servicing of marine engines and generator sets pres-ents unique problems. In many cases boats cannot be moved to a repair facility. Marine engines cannot be compared to the servicing of automobiles, trucks or even farm equipment. Failures often occur in remote areas far from competent assistance. Marine engines are taxed far more severely than auto or truck engines; therefore, maintenance schedules must be adhered to more strictly.
Failures begin with minor problems that are overlooked and become amplifi ed when not corrected during rou-tine maintenance.
As operator, it is your obligation to learn about your equipment and its proper maintenance. This is not a comprehensive technical service manual. Nor will it make the reader into an expert mechanic. Its aim is to aid you in maintaining your unit properly.
Introduction
D, T, Q & H
MP - Northern Lights marine generator setModel number
4 Cylinder 4.5 LitersModel number
6 Cylinder 6.8 Liters
Model Numbers
Model numbers give the unit's application, block model, aspiration, and RPM:
D - Naturally aspirated T - Turbocharged Q - 1200 RPM H - High output
+ +
Northern Lights® naturally aspirated, 1800 RPM marine diesel generator set with a John Deere Powertech 4045 or 6068 engine block.
MP445D,MP668D
MP 445 (4045) or 668 (6068)
=
= MP65C =
2
Northern Lights® turbocharged marine genera-tor set with a John Deere Powertech 4045Hor 6068H engine block.
Northern Lights® turbocharged, 1200 RPM marine generator set with a John Deere Pow-ertech 6068 engine block.
Northern Lights® high output marine genera-tor set with a John Deere Powertech 4045H or 6068H engine block.
40 kW Northern Lights® commercial marine gen-erator set with a John Deere Powertech 4045D engine block.
55 kW Northern Lights® commercial marine generator set with a John Deere Powertech 4045T engine block.
65 kW Northern Lights® high output marine generator set with a John Deere Powertech 4045T engine block.
80 kW Northern Lights® commercial marine generator set with a John Deere Powertech 6068T engine block.
99 kW Northern Lights® commercial marine generator with a John Deere Powertech 6068T engine block.
MP445T,MP668T
MP445H,MP668H
=
=
=MP80C
MP99C
Serial NumbersWhen referencing Alaska Diesel Electric equipment by serial number, please refer only to the number stamped on the Northern Lights® serial number plate.
MP668QT
MP40C =
=MP55C
=
OMP 06-02
CAUTION: This symbol is used throughoutthis book to alert you to possible danger areas.Please take special notice of these sections.
A warranty registration certifi cate is supplied with your set. The extent of coverage is described in the Limited Warranty Statement. We recommend that you study the statement carefully.
NOTE: If the warranty is to apply, the servicing instructions outlined in this manual must be
followed. If further information is needed, please contact an authorized dealer or the factory.
CAUTION: Accident reports show that careless use of engines causes a high percentage of accidents. You can avoid accidents by observing these safety rules. Study these rules carefully and enforce them on the job.
• Use caution in handling fuel. Never refuel a hot or running engine. Do not smoke while fi lling fuel tank or servicing fuel system.
• Keep your hands, feet, hair and clothing away from power-driven parts.
• Check for any loose electrical connections or faulty wiring.
• Engines should be operated only by knowledge-able, qualifi ed personnel.
• Look completely around engine to make sure that everything is clear before starting.
• Do not operate an engine that isn't in proper work-ing order. If an unsafe operating condition is noted, tag the set and control panel so others will also know about the problem.
• Provide fi rst aid kits.
• Never leave engine without proper security.
• Turn the coolant tank cap slowly to relieve pres-sure before removing. Add coolant only when the engine is stopped and cool.
• Mount a fi re extinguisher near engine.
• Always disconnect the battery ground strap before making adjustments.
• Operate engines in properly ventilated areas.
• Keep trash and other objects away from engine.
• Escaping fl uids under pressure can penetrate your skin. Use a piece of cardboard or wood, not your hands, to search for leaks.
• Avoid wearing loose clothing when working around engines.
• Do not oil or grease engine while it is running.
Safety Rules
Warranty
3
CALIFORNIAProposition 65 Warning:
Diesel engine exhaust and some of its constitu-ents are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
OMP 06-02
1. Expansion Tank 2. Raw Water Pump 3. Drive Belt 4. Lube Oil Fill 5. Lube Oil Filter 6. Fuel Lift Pump 7. Lube Oil Dipstick
8. Lube Oil Drain 9. Electric Starter 10. Fuel Manifold 11. DC Circuit Breaker 12. Air Cleaner13. D.C. Alternator 14. Wet Exhaust Elbow
15. Exhaust Manifold Drain 16. Engine Block Drain 17. Fuel Injection Pump 18. Heat Exchanger Zinc (2)19. Heat Exchanger Drain 20. Heat Exchanger 21. Coolant Fill
22. Thermostat Cover 23. Fuel Injectors (4)24. A.V.R. Fuse25. Fuel fi lter
4
Figure 1: MP445D
MP Component Locations
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MP Component Locations
5
1. Expansion Tank 2. Injection Pump Drive Coupling Access Cover Plate 3. Drive Belt Cover 4. Lube Oil Fill 5. Lube Oil Filter 6. Optional Power Takeoff
7. Optional Flow Switch 8. Fuel Lift Pump 9. Lube Oil Dipstick 10. Fuel Manifold 11. Lube Oil Drain 12. Electric Starter 13. DC Circuit Breaker 14. Air Cleaner
15. Optional Governor Actuator 16. DC Alternator 17. Wet Exhaust Elbow 18. Exhaust Manifold Drain 19. Engine Block Drain 20. Fuel Injection Pump 21. Optional Hydrolastic Mount
Figure 2: MP445H (note: MP445T models have similar component locations).
22. Heat Exchanger Zinc (2) 23. Heat Exchanger Drain 24. Heat Exchanger 25. Coolant Fill 26. Thermostat Cover 27. Fuel Injectors (4) 28. Turbocharger29. A.V.R. Fuse30. Fuel Filter
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Figure 3: MP668T (note: components of MP668QT are in a similar location).
MP Component Locations
1. Coolant Fill 2. Expansion Tank 3. DC Alternator 4. Lube Oil Fill 5. Lube Oil Filter 6. Fuel Lift Pump 7. Lube Oil Dipstick 8. Lube Oil Drain
17. Heat Exchanger Zinc (2)18. Heat Exchanger Drain 19. Heat Exchanger20. Raw Water Pump21. Fuel Injectors (6)22. Thermostat Cover23. Optional Hydrolastic Mounts
9. Air Cleaner 10. DC Circuit Breaker 11. Turbocharger 12. Wet Exhaust Elbow 13. Exhaust Manifold Drain 14. Electric Starter 15. Engine Block Drain 16. Fuel Injection Pump
24. Optional Governor Actuator25. Drive Belt Cover26. Fuel Manifold27. A.V.R. Fuse28. Fuel Filter
6
OMP 06-02
Northern Lights Control Panels
Figure 4-A: Series 3 Generator Control Panel
7
1. SHUTDOWN BYPASS SWITCH This switch bypasses the safety shutdown feature
during the starting process.
2. ENGINE CONTROL SWITCH To start the engine, hold this switch in the START
position until the engine is running. NOTE: Excessive cranking of marine sets equipped
with water lift muffl er systems can cause engine damage.
After the engine starts, release the switch and it will return to RUN position. To stop the engine, hold the switch in the STOP position.
NOTE: The rocker switch is used on Series 1 panels only, and has a light that glows when the set is running.
3. OIL PRESSURE GAUGE The oil pressure gauge shows the oil pressure in
the engine lubricating system. If the pressure drops below 15 PSI at a speed higher than idling, stop the engine and investigate.
4. COOLANT TEMPERATURE GAUGE Water temperature gauge shows the temperature of
the cooling water. If the gauge registers over 200° or drops below 140°, stop the engine and investi-gate.
5. HOUR METER Keeps track of the engine running time.
6. DC VOLTMETER When the engine is running, it indicates the voltage
output of the alternator.
Figure 4-B: Series 1-B Generator Control Panel
Figure 4-C: Series 3C Generator Control Panel
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Figure 5: Series 4 Generator Control Panel
7. AC VOLTMETER The voltmeter shows the generator output volt-
age, phase to phase. If the voltage fl uctuates greatly from the normal reading, shut down the unit and investigate.
8. FREQUENCY METER Indicates engine speed. The correct reading for
1800 and 1200 RPM sets is 60 Hz. For 1500 RPM sets, it is 50 Hz. If meter does not indi-cate correct hertz, stop and investigate.
9. AMMETER SELECTOR SWITCH The ammeter switch is used for checking each
phase for load condition. Leave it in the ON position while the engine is running.
10. AC AMMETER The ammeter indicates the phase load. Check
for load unbalance. If the unbalance is greater than 30%, have an electrician balance the load properly. This will ensure longer generator life and better economy.
1. SHUTDOWN BYPASS SWITCH This switch bypasses the safety shutdown feature
during the starting process.
2. ENGINE CONTROL SWITCH The control switch starts and stops the engine.
3. OIL PRESSURE GAUGE The oil pressure gauge shows the oil pressure in
the engine lubricating system. If the pressure drops below 15 PSI at a speed higher than idling, stop the engine and investigate.
4. COOLANT TEMPERATURE GAUGE Water temperature gauge shows the temperature of
the cooling water. If the gauge registers over 200° or drops below 140°, stop the engine and investi-gate.
5. HOUR METER Keeps track of the engine running time.
6. DC VOLTMETER When the engine is running, it indicates the voltage
output of the alternator.
Northern Lights Control Panel
8
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Operating Procedures
BEFORE STARTING1. Check the water level by removing the pressure cap from the expansion tank. In order to give the
cooling water room to expand, the level should be about 1 3/4 in. (4-5 cm) below the fi ller cap sealing surface when the engine is cold. When fi lling with coolant, the venting cock on top of the turbocharger should be opened to ensure that no air pockets form in the cooling system (see Service Point #14).
CAUTION: Use protective clothing and open the fi ller cap carefully when the engine is warm to prevent burns.
2. Check the oil level in the crankcase with the dipstick. The oil level should be between the “waffl ed area” and the “oo”. Never allow the level to go below the “oo”. Always add the same viscosity of oil as is already in the crankcase (see Service Point #1).
3. Check the fuel tank level and open any fuel valves.4. Close the seacock, check and clean the strainer and
reopen the seacock.5. Place the battery switch in the ON position.
NOTE: The battery switch must always be kept ON while the engine is running. If the switch is turned OFF while the engine is running, the battery charging regulator could be ruined.
GENERATOR
Starting 1. While holding the Shutdown Bypass switch in the
ON position, push the Engine Control switch to the START position
2. As soon as the engine starts, release both switches. Do not crank the starter for more than 20 seconds. 3. If the engine fails to start the fi rst time, be sure the
starter has stopped before reengaging.
Operating1. Check Gauges Often: Oil pressure must be above 29 PSI. The D.C. voltmeter should read between 13
and 14 volts (26-28 volts, 24 volt systems) at 60°F (16°C) ambient temperature. Water temperature gauge must be below 200°F (94°C).
2. Check AC voltage and frequency meters (Series 4 Panel). If gauges deviate from normal levels, shut down the set and investigate.
3. Let the unit run unloaded for a three to fi ve minute warm-up period before applying load.
4. Do not add full electrical load until engine is at maximum operating temperature.
Shutdown1. Unload the generator and run for three to fi ve minutes
for cool down period.2. Turn the Engine Control Switch to the OFF position.3. Close the sea cock and fuel valves, and put the battery
switch in the OFF position if the unit will be off for an extended period.
NOTE: Do not turn the battery switch to OFF while the engine is running.
SHUTDOWNS AND ALARMS1. Your unit is fi tted with a system to protect it from high
water temperature or low oil pressure.
a. Generator sets have shutdown systems to stop the engine. They have no warning horns. b. Other alarms and shutdowns are available as optional equipment.
NOTE: Do not rely on your warning or shutdown system to the exclusion of careful gauge monitoring. Watching your gauges can prevent damage to the unit and dangerous power losses.
2. Do the following when your shutdown system is activated:
a. Check the temperature gauge. If the temperature is above 205°F (97°C), shut off the engine immediately. b. Use the Trouble Shooting Guide on pages 25- 26 to isolate the cause of the overheat.
CAUTION: Do not remove the water fi ll cap of an overheated engine. Escaping high temperaturesteam can cause severe burns. Allow the engine to cool and then remove the cap slowly, using protective clothing.
c. Make repairs and restart after the temperature gauge registers below 180°F (83°C). d. Watch the temperature gauge regularly and turn off the unit if the temperature rises above 200°F (94°C). Repeat the troubleshooting process.
9
OMP 06-02
Operating Procedures
3. If the shutdown is activated and the temperature
gauge shows temperature within normal temperature range:
a. Check the engine crankcase oil level. b. If the oil level is low, fi ll with recommended lubricating oil and restart. Watch the oil pressure gauge carefully and shut off the engine if it does not show a normal reading after a few seconds of operation. c. If the oil level is normal, DO NOT restart the engine. Call your Northern Lights or Lugger dealer for assistance.
BREAK-IN PERIOD
1. The fi rst 100 hours on a new or reconditioned engine are critical to its life and performance.
2. Constantly check the engine temperature and oil pressure gauges.
3. Oil consumption is greater during break-in as piston rings and cylinder liners take time to seat.
4. Break-In Oil Changes: Change engine oil and fi lter at 50 hours. Change oil and fi lter again at 100 hours (See Gear Owner's Manual for break-in oil change procedures. Consult Lubricants Section for oil recommendation).
OPERATING INSTRUCTIONS
Generator sets: Maintain at least a 75% load on your set for the fi rst 100 hours. If this is not possible, maintain no less than a 50% load to ensure proper seating of the piston rings. Vary the load to help seat rings.
10
OMP 06-02
The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your marine engine or generator set. More detailed coverage of each Service Point (SP) is listed on the page noted in the ‘page’ column.
DAILY: SP1 Check oil level in engine SP7 Check primary fuel fi lter SP14 Check cooling water level AFTER FIRST 50 HOURS: SP2 Change engine oil SP3 Change lube oil fi lter
EVERY 50 HOURS: SP22 Check electrolyte in batteries
FIRST 100 HOURS: SP2 Change engine oil SP3 Change lube oil fi lter
EVERY 250 HOURS: SP2 Change engine oil SP3 Change lube oil fi lter SP4 Check air cleaner SP8 Change primary fuel fi lter element SP12 Check turbocharger air, oil & cooling lines for leakage
SP18 Check zinc electrodes
AFTER FIRST 600 HOURS: SP6 Adjust valves
EVERY 600 HOURS / YEARLY: SP4 Replace air cleaner SP5 Check V-belt condition SP9 Change secondary fuel fi lter SP10 Check injectors SP13 Check turbocharger boost pressure SP15 Check and fl ush cooling system SP19 Change impeller in raw water pump SP23 Check the state of the charge of the batteries
EVERY 1200 HOURS: SP6 Adjust valves
EVERY 2400 HOURS: SP11 Check fuel injection pump SP16 Check and clean heat exchanger SP17 Check and clean gear oil cooler
1) Perform all maintenance once a year even if hour level has not been reached.2) Consult manufacturer's maintenance schedule, note on chart.3) Whenever necessary.
Servicing Schedule Chart
SERVICE 50 250 600 1200 2400 POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours
ENGINE: SP1 14 Check oil level • SP2 14 Change engine oil 1) • SP3 14 Change lube oil fi lters 1) • SP4 14 Check (replace) air cleaner 1) 3) • • SP5 Check belt condition 1) • SP6 15 Check valve clearances 1) •
FUEL SYSTEM: SP7 16 Check primary fi lter (Racor) 2) • SP8 16 Change primary fi lter element (Racor) 2) 3) • SP9 16 Change secondary fuel fi lter 1) 3) • SP10 17-18 Check injectors 1) • SP11 18-20 Check fuel injection pump • TURBOCHARGER: SP12 21 Check air, oil & cooling water lines for leakage 1) • SP13 21 Check boost pressure • COOLING SYSTEM: SP14 12 & 23 Check cooling water level • SP15 23 Check and fl ush cooling system 1) • SP16 23 Check and clean heat exchanger 1) • SP17 Check and clean gear oil cooler 1) • SP18 23-24 Check zinc electrodes 1) 3) • SP19 24 Change impeller in raw water pump 1) 3) • ELECTRICAL SYSTEM: SP22 25 Check electrolyte level in batteries 1) 3) • SP23 25 Check condition of batteries with hydrometer 1) • OUT OF SERVICE: SP24 27 Winterizing or out-of-service 3)
11
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ServicePoint HOURS/DATE
Service Record
OPERATION
12
50 HOURS
SP23 Check electrolyte
in batteries
250 HOURS
SP2 Change engine oil
SP3 Change lubricating oil fi lters
SP4 Check air cleaner
SP7 Change primary fuel fi lter element
SP12 Check turbocharger air, oil & cooling lines for leakage
SP18 Check zinc electrodes
600 HOURS
SP4 Replace air cleaner
SP5 Check belt condition
SP9 Change secondary fuel fi lter
SP10 Check injectors
SP13 Check turbocharger boost pressure
SP15 Check and fl ush cooling system
SP19 Change impeller in raw water pump
SP23 Check state of charge of batteries
EVERY 1200 HOURS
SP6 Check valve clearances
2400 HOURS
SP11 Check fuel injection pump
SP16 Check and clean heat exchanger
SP17 Check and clean reverse gear oil cooler
OMP 06-02
LUBRICATIONBreak-in oil1. Use one of the following during the fi rst 100 hours
of operation: a. John Deere Engine Break-In Oil b. API Service CE oil c. ACEA Specifi cation E12. Do not use John Deere PLUS-50 oil or engine oils
meeting API CG4, API CF4, ACEA E3, or ACEA E2 performance levels during the fi rst 100 hours of operation of a new or rebuilt engine. These oils will not allow the engine to break-in properly.
Lubrication - General1. Use only clean, high quality lubricants stored in
clean containers in a protected area.2. These oils are acceptable after the fi rst 100 hours: a. API Service CC/CD single viscosity oils. b. API Service CD/CG-4/CF-4 multi-viscosity oils. c. ACEA Specifi cation E3/E2 multi-viscosity oils. d. CCMC Specifi cation D5 and Mercedes Benz
MB228.3. e. CCMC Specifi cation D4 and Mercedes Benz
MB228.1.3. Use the proper weight oil for your average operation
temperature.
4. Some increase in oil consumption may be expected when SAE 5W and SAE 5-20W oils are used. Check oil level frequently.
5. Never put additives or fl ushing oil in crankcase.
SP1. CHECK ENGINE OIL LEVEL1. Check the oil level in the crankcase, with the oil
dipstick, daily.2. The oil level must be between the “Waffl ed area” and
the “oo”. Never allow the level to go below the “oo”. 3. Always add the same viscosity of oil as is already in
the crankcase.
Marine Generator Sets: a. Remove plug from outlet in base frame. Screw in owner-supplied drain hose. b. Open valve at oil pan outlet. After oil has been drained into suitable container, close valve, remove drain hose and replace plug in base frame outlet. c. Refi ll engine with recommended oil.4. Engine Lube Oil Capacity:
SP3. CHANGING OIL FILTER1. Change the lube oil fi lter every 250 hours.2. Use a fi lter wrench to remove old fi lter. Dispose of
fi lter in approved manner.3. Make sure the gasket from the old fi lter is removed
and discarded.4. Lubricate the rubber gasket on the new fi lter and screw
it on nipple until gasket meet the sealing surface.5. Using hands only, no wrench, tighten fi lter one-half turn
farther. Overtightening can do damage to fi lter housing.6. Fill engine with recommended oil. Start engine and
check for leakage. Stop engine and check oil level. Add additional oil if necessary.
SP4. AIR CLEANER1. Inspect air cleaner every 100 hours. Replace fi lter
every 600 hours, or yearly, whichever comes fi rst.2. Clean the rubber tube at the cleaner. Loosen the hose
clamp and the attaching strip for the cleaner.3. Make sure the rubber tube is in good condition and
that new fi lter is absolutely clean and installed prop-erly.
4. Start the engine and check for leaks.
NOTE: Make absolutely sure no impurities enter the engine while changing the element. Do not run the engine with the air cleaner removed.
Air Single Multi Temperature Viscosity Viscosity
Above 32°F (0°C) SAE-30W SAE15-40W
-10°F to 32°F (-23°C to 0°C) SAE-10W SAE10-30W Below -10°F (-23°C) SAE-5W SAE5-20W
445 Series 14 qts. 13.2 liters 668 Series 18 qts. 17.0 liters
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Servicing
SP2. OIL CHANGES1. Using the oil recommended above, change the engine oil
and fi lter after the fi rst 50 hours of operation, the fi rst 100 hours and every 250 hours thereafter.
2. During intermittent cold weather operation, change oil every 100 hours or six weeks, whichever comes fi rst.
3. Change oil at any seasonal change in temperature when a new viscosity of oil is required.
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SP6. VALVE CLEARANCESThe following special tools will be needed: JDE 820 or JDE 83 Flywheel Turning Tool. JDE 81-4 Timing Pin.1. Check the valve clearances after the fi rst 600 hours,
the fi rst 1200 hours and every 1200 hours thereafter.2. Remove rocker arm cover with ventilator tube.3. Remove plastic plugs in engine timing holes on front
side of fl ywheel. 4. Rotate fl ywheel in clockwise direction (viewed from
water pump) with the Flywheel Turning Tool until the Timing Pin engages timing hole in the fl ywheel. Both rocker arms for No. 1 cylinder will be loose at Top Dead Center. If they are not, remove the timing pin and rotate the fl ywheel one complete turn and reinstall the timing pin in the fl ywheel.
5. Valve clearances must be checked with the engine cold.
Intake Valve: 0.012-0.015 in. (0.31-0.38 mm) Exhaust Valve: 0.016-0.019 in. (0.41-0.48 mm)
FUELS - GENERAL1. Use only clean, high quality fuels of the following
specifi cations, as defi ned by ASTM designation D975 for diesel fuels:
a. Use grade no. 2 diesel at ambient temperatures above freezing 30°F (0°C). b. Use grade No.1 at ambient temperatures below freezing and for all temperatures at an altitude of above 5,500 ft. (1500 meters).2. Sulphur content should not exceed 0.5% (preferably
less than 0.5%).3. The cetane number should be a minimum of 45.4. DO NOT use these unsuitable grades of fuel: a. Domestic heating oils, all types. b. Class B engine. c. Class D domestic fuels. d. Class E, F, G or H industrial or marine fuels. e. ASTM-D975-60T No. 4-D and higher number fuels. f. JP4
14
Servicing
4-CYLINDER ENGINES:
NOTE: Firing order is 1 - 3 - 4 - 2
Reproduced by permission of Deere & Company, c2000. Deere & Company.All rights reserved.
A - Front of EngineB - No. 1 Piston at TDC Compression StrokeC - No. 4 Piston at TDC Compression StrokeE - Exhaust ValveF - Intake Valve
Lock No. 1 piston at TDC compression stroke (B).
Adjust valve clearance on No. 1 and No. 3 exhaust valves and No. 1 and No. 2 intake valves.
Rotate fl ywheel 360°. Lock No. 4 piston at TDC com-pression stroke (C).Adjust valve clearance on No. 2 and No. 4 exhaust valves and No. 3 and No. 4 intake valves.
6-CYLINDER ENGINES:
NOTE: Firing order is 1 - 5 - 3 - 6 - 2 - 4
Reproduced by permission of Deere & Company, c2000. Deere & Company. All rights reserved.
A - Front of EngineB - No. 1 Piston at TDC Compression StrokeC - No. 6 Piston at TDC Compression StrokeE - Exhaust ValveF - Intake Valve
Lock No. 1 piston at TDC compression stroke (B).
Adjust valve clearance on No. 1, No. 3, and No. 5 exhaust valves and No. 1, No. 2, and No.4 intake valves.
Rotate fl ywheel 360°. Lock No. 6 piston at TDC compression stroke (C).
Adjust valve clearance on No. 2, No. 4, and No. 6 exhaust valves and No. 3, No. 5, and No. 6 intake valves.
OMP 06-02
FUELS - GENERAL (continued) 5. Storing fuel: a. Keep dirt, scale, water and other foreign matter out of fuel. b. Avoid storing fuel for long periods of time. c. Fill the fuel tank at the end of each day's operation. This will reduce condensation.SP7-9. FUEL FILTERS1. Your engine or generator set should have a primary
fuel fi lter installed. We recommend the Racor brand of fuel fi lter - water separators.
a. Check the primary fuel fi lter daily as recommended by the fi lter manufacturer. Empty the collection bowl as necessary. b. Change the element every 250 hours or whenever necessary. c. If the bowl fi lls with water, change the primary and secondary elements immediately.2. Change secondary fuel fi lter every 600 hours. NOTE: The fuel fi lter on the engine is considered the
“secondary fuel fi lter”. The engine will be fi tted with a quick change disposable secondary fuel fi lter.
a. Turn off the fuel. b. Open the fi lter drain plug (Figure 6-A) and drain the fi lter.
Figure 6: Secondary Fuel fi lter
c. Remove the secondary fuel fi lter by turning the fi lter clamp (Figure 6-B) counter clockwise until the fi lter cartridge (Figure 6-C) slides out.
15
Servicing
NOTE: Before installing a new fi lter cartridge make sure the surfaces where the cartridge comes in contact with the mounting plate are absolutely clean. Dirt can be washed into the fuel injection system. This may result in severe damage to the fuel injection pump or nozzles. d. Install new fi lter cartridge. e. Fuel fi lter cartridge number is: 24-51005 f. Turn on the fuel.
BLEEDING THE FUEL SYSTEM CAUTION: Escaping diesel fuel under pressure can penetrate the skin, causing serious personal injury. Before disconnecting lines be sure to relieve all pres-sure. Before applying pressure to the system be sure all connections are tight and the lines, pipes and hoses are not damaged. Fuel escaping from a very small hole can be almost invisible. Use a piece of cardboard or wood rather than the hands to search for suspected leaks. If injured by escaping fuel, see a doctor at once. Serious infection or reaction can develop if proper medical treatment is not administered immediately.
1. Whenever the fuel system has been opened for ser-vice, (lines disconnected, fi lter changed, etc.) it will be necessary to bleed air from the system.
a. To bleed the fuel system, loosen the bleed plug (Figure 6-D) on the fuel fi lter. Operate the primer pump lever on fuel transfer pump (see component locations) until most of the air bubbles are expelled and clear fuel escapes the bleed plug. Tighten the bleed plug. b. If the engine will not start, it may be necessary to loosen the fuel supply pipe at the pump. Operate primer lever of fuel supply pump until fuel fl ow is free from air bubbles. Retighten fuel supply line to 22 ft. lb. (30 N•m). c. If engine still doesn't start, loosen fuel line connection at injection nozzle. Always use a back up wrench when loosening or tightening fuel lines at nozzles and injection pump to avoid damage. With throttle on full, crank the engine over with the starter until fuel without air fl ows from the loose fuel pipe connection. Repeat procedure for remaining nozzles, if necessary, until engine starts or until air has been removed from system. Tighten the connections to 20 foot lb. (27 N•m).
OMP 06-02
SP10. INJECTORS 1. Fuel injectors should be checked by a Lugger-North-
ern Lights dealer or qualifi ed fuel injection shop every 600 hours.
2. Injector Removal: You will need the following special tools: JDE38A—Injection Nozzle Puller JDE39—Nozzle Bore Cleaning Tool JD258—Pilot Tool a. Before removal, carefully remove all dirt from the cylinder head around fuel injection nozzles. Clean with compressed air to prevent dirt from entering the cylinders or valve seats. Plug the bore in the cylinder head after each fuel injection nozzle has been removed. Cap fuel line openings as soon as they are disconnected. b. Immediately fi t protective caps over the nozzle tips and the line connections to avoid handling damage. c. Do not bend the fuel delivery lines. When loosening the fuel pressure lines, hold male union of nozzle line stationary with a backup wrench. d. Loosen nuts to remove leak-off lines and T-fi ttings and disconnect fuel injection line from nozzle.
NOTE: When all fuel injection nozzles have to be removed, disconnect leak-off line assembly at fuel tank, at injection pump, and at each nozzle T-fi tting. Lift off complete leak-off line as an assembly.
e. Remove cap screw, clamp and spacer. f. Pull injection nozzle out of cylinder head with JDE38A Injection Nozzle Puller.
NOTE: Do not use screwdrivers, pry bars, or similar tools for this as they might damage the injection nozzle.
3. Clean Injector Bore: Always turn the tool clockwise through the bore
even when removing from bore, otherwise tool may become dull.
a. Clean nozzle bore with JDE39 Nozzle Bore Cleaning Tool. Blow debris from bore with compressed air and plug the bore to prevent entry of foreign material.4. Clean injection nozzles: a. Remove carbon stop seal (Figure 7-A) and upper sealing washer (Figure 7-B), using a needle-nose pliers. Discard seals.
b. Clean exterior of nozzle by soaking in clean solvent or diesel fuel. Clean tip with brass wire brush.
Figure 7 Reprinted by permission of Deere & Company, RG6300 Deere & Company, All rights reserved.
NOTE: Do not scrape or disturb the tefl on coating on the nozzle body above the carbon stop seal groove. This coating will become discolored during normal operation, but this is not harmful. Do not use a motor driven brush to clean up nozzle body.
Figure 8
5. Install seals on injection nozzle.
NOTE: Each time an injection nozzle is removed from the cylinder head, replace carbon stop seal (B) with a new one.
a. Position JD258 (ROS16477) Pilot Tool (Figure 8-C) over nozzle tip. If Pilot Tool (included in cleaning kit) is not available, use a No. 16189 Nozzle Protector Cap found on every new or re- placement nozzle. b. Position a new carbon stop seal (Figure 8-B) on pilot tool. Use a new seal washer (Figure 8-A) to help slide the carbon seal into place until it seats in its groove on nozzle body. c. Continue to slide upper sealing washer onto nozzle body until it seats against inlet fi tting.
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Servicing
OMP 06-02
6. Install injection nozzles:
NOTE: Before installing injection nozzles, make sure nozzles are clean and free from oil or grease. Do not grease or oil the nozzles.
a. Remove plug (if installed previously) from nozzle bore in cylinder head and blow out bore with compressed air. b. Make sure that the sealing surface of the cylinder head (on which the seal washer will be resting) is smooth and free of damage or dirt. This could prevent proper sealing. Dirt and roughness could also cause distortion to nozzle when the attaching screw is tightened, making the valve stick. c. Install nozzle in cylinder head using a slight twisting motion as nozzle is seated in bore.
Figure 9: Shows relationship of parts required for installation.
d. Install spacer and cap screw. Do not tighten capscrew at this stage. e. Connect fuel pressure line to nozzle. Leave connection slightly loose until air is bled from system. f. Tighten nozzle hold-down cap screws to 27 foot lb. (37 N•m). g. Install leak-off assembly. h. Bleed air from loose injection line connection. Tighten connection using two wrenches.
SP13. INJECTION PUMP1. Since operating conditions may vary considerably,
it is diffi cult to give a defi nite service interval. But, as a rule, the pump settings, maximum speed, idle speed and exhaust smoke should be checked by your dealer after every 2400 hours of operation. Service of the fuel injection pump should only be done if checks indicate pump malfunction.
2. Black smoke can be an indication of pump malfunctions. Before servicing pump, check the
other possible causes. a. Check cleanliness of air fi lter. b. Check valve clearances. c. Clean and check injectors.3. Any repair which involves disassembly of the injection
pump must be carried out by specially-trained mechanics with the proper tools and test devices.
NOTE: All warranties on the engine become null and void if the injection pump seals are broken by unau-thorized persons.
DB4 AND DB2 INJECTION PUMPS – REMOVAL All Stanadyne DB2 and DB4 injection pumps will
have a retained drive shaft (shaft stays in pump when pump is removed from engine).
1. Clean the fuel injection pump, lines and area around the pump with cleaning solvent or a steam cleaner.
IMPORTANT: Never steam clean or pour cold water on a fuel injection pump while the pump is running or while it is warm. Doing so may cause seizure of internal rotating pump parts.
2. Disconnect shutoff cable and speed control link-age or cold start switch, if equipped. Disconnect electrical connection to shutoff solenoid or throttle positioning solenoid. Tag electrical wires for correct reassembly.
IMPORTANT: Always use a backup wrench when loosening or tightening fuel lines at injection pump
so that discharge fi ttings are not altered which will prevent internal pump damage.
3. Disconnect fuel return line (Figure 10-A) and fuel supply line (Figure 10-C).
Figure 10 Reproduced by permission of Deere & Company, c.2000. Deere & Company,. All rights reserved.
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Servicing
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IMPORTANT: Injection pump mounting fl ange timing mark (Figure 12-A ) and front plate timing mark (Figure 12-B) presence and alignment MUST be veri-fi ed before removing pumps from engine. DO NOT reference internal timing marks (on pump cam ring and governor weight retainer). If timing mark is not clearly visible on front plate, scribe a visible reference mark as accurately as possible in-line with mark on pump fl ange.
10. Remove three injection pump mounting stud nuts. Remove injection pump from mounting studs.
11. Plug or cap all openings on injection pump and take pump to dealer for service
DB4 & DB2 INJECTION PUMP – INSTALLATION1. Lubricate a new square sealing ring with clean
engine oil. Install ring into groove on front face of pump mounting fl ange. Slide injection pump onto mounting studs while inserting pump shaft into drive gear.
2. Check pump shaft and index pin for proper alignment with pump drive gear key slot.
IMPORTANT: Shaft roll pin may be easily damaged if improperly assembled. Pump drive gear should not move when initially installing pump index pin into drive gear key slot.
3. Install injection pump partially onto mounting studs without engaging pump pilot hub into engine front plate.
IMPORTANT: DO NOT tighten hex nuts more than three full turns on mounting studs. Pump drive shaft index pin may be damaged if pin is not properly aligned with drive gear key slot and if the nuts are tightened more than three turns.
4. Install three fl at washers, lock washers, and hex nuts onto pump mounting studs. Tighten nuts three turns only so that pump will not fall off mounting studs.
NOTE: The pump drive gear should begin to move forward (away from engine front plate) with the pump when fl ange is approximately 1/8 in. (3.2mm) away from engine front plate.
4. Disconnect all fuel delivery (pressure) lines (Figure 10-B) from injection pump using a suitable 17mm deep-well crowsfoot socket.5. Remove injection pump drive gear cover. Remove
drive gear retaining nut and washer from end of pump shaft. Be careful not to let washer fall inside timing gear cover.
NOTE: The injection pump drive gear fi ts snugly onto a tapered drive shaft and indexed by a hollow pin or Woodruff key installed in drive shaft
6. Attach JDG670A Drive Gear Puller (Figure 11-A) to injection pump drive gear as shown.
NOTE: Replace 6mm Grade 12.9 cap screws (C) as needed.
7. Evenly tighten the two 6mm, Grade 12.9 screws (threaded in drive gear) and snugly tighten center forcing screw (Figure 11-B) against end of pump shaft.
Figure 11. Reproduced by permission of Deere & Company, c.2000. Deere & Company. All rights reserved.
8. Tighten center forcing screw until pump drive gear is free from tapered shaft. Remove JDG670A puller (Figure 11-A) and screws from drive gear.
9. Check to make sure that timing marks on back side of front plate (Figure 12-A) and injection pump fl ange (Figure 12-B) are present and properly aligned. This assures that repaired or replacement pump can be properly timed to engine when installed.
Figure 12. Reproduced by permission of Deere & Company, c.2000. Deere & Company. All rights reserved.
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Servicing
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5. Install pump mounting fl ange fl ush to engine front plate with drive gear held fl ush against front side of engine front plate.
IMPORTANT: Do not use tightening force of pump mounting stud nuts to pull pump shaft into drive gear I.D.
6. With the pump shaft index pin properly engaged in the drive gear key slot, fi nger tighten mounting stud nuts.
7. Push pump drive gear fi rmly onto shaft taper. Install washer and retaining nut (Figure 13-C) onto end of shaft. Tighten retaining nut to 90 lb-ft. (122 N•m) for DB2, 150 lb-ft. (203 N•m) for DB4.
Figure 13 Reproduced by permission of Deere & Company, c.2000. Deere & Company, All rights reserved.
IMPORTANT: Do not overtighten cap screws on pump cover plate to avoid damage to O-ring.
8. Install access cover plate using a new gasket. Apply LOCITE 242 (TY9370) to cap screw threads and tighten to 1.7 lb-ft. (2 N•m).
9. Align timing mark on the pump fl ange (Figure 14-B) with timing mark on the cylinder block front plate (A).
Figure 14 Reproduced by permission of Deere & Company, c.2000. Deere & Company, All rights reserved.
10. Tighten the three hex nuts securing the pump to the front plate to 20 foot lbs. (27 N•m).
11. Connect injection pump pressure lines (Figure 15-E). Beginning with outlet connection to #1 cylinder (Figure 16-B) and continue around the pump head in counterclockwise direction, attaching lines in same order as engine fi ring (1-5-3-6-2-4 on 6-cylinder engines and 1-3-4-2 on 4-cylinder engines).
Figure 15 Reproduced by permission of Deere & Company, c.2000. Deere & Company, All rights reserved.
Figure 16 Reproduced by permission of Deere & Company, c.2000. Deere & Company, All rights reserved.
12. Tighten fuel delivery (pressure) lines to 20 foot lbs. (27 N•m), using a suitable 17mm deep-well crows-foot socket.
IMPORTANT: Always use a backup wrench when loosening or tightening fuel delivery lines at fuel injection pump, so that the pump discharge fi ttings are not altered. This prevents possible internal pump damage.
13. Connect fuel supply line (Figure 15-C) and fuel return line (Figure 15-D).
14. Connect fuel shutoff cable and speed control linkage, if equipped. Install and securely tighten electrical connections to shutoff solenoid and throttle position-ing solenoid, if equipped. Connect cold start switch, if equipped.
15. Bleed air from fuel system as outlined on page 15. Start engine and run for several minutes. Check the entire system for leaks.
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Servicing
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SP12. TURBOCHARGER1. Check for air leaks every 200 hours. Air leakage will lower engine output and may cause black
exhaust smoke and soot.2. Listen along air line while engine is running. A whistling or hissing sound indicates leakage.3. Leakage on the pressure side, between turbo and
engine, can be found by applying soapy water to the air line.
4. Tighten the hose clamps, replace hose or gaskets as required.
5. Check to see that the lubrication and cooling lines are tight and without leaks.
SP13. TURBO BOOST1. This check measures the amount of air the turbo
is pushing into the engine. It should be done by an authorized dealer every 600 hours.
2. On the inlet manifold there is a 1/8" NPT threaded port. Remove the plug and install the boost gauge hose. Refer to your engine specifi cations for correct pressure.
COOLING REQUIREMENTS1. To meet cooling system protection requirements, the
coolant solution must consist of: a. Quality water b. Ethylene glycol concentrate (EGC ) commonly known as antifreeze. c. Supplemental coolant additives (SCA's).2. A coolant solution of ethylene glycol concentrate
(EGC-antifreeze), quality water and supplemental coolant additives (SCA's) MUST be used YEAR ROUND to protect against freezing, boil-over, liner erosion or pitting and to provide a stable, noncorro-sive environment for cooling system components.
3. Ethylene glycol coolant concentrate (antifreeze) normally DOES NOT contain the SCA chemical inhibitors needed to control liner pitting or ero-sion, rust, scale, and acidity.
LINER EROSION (PITTING)1. Cylinder liner walls (Figure 17-A) which are in contact
with engine coolant (Figure 17-B) can be eroded or pitted unless the proper concentration and type of SCA's are present in the coolant. Water pump impel-lers are also susceptible to pitting.
2. Vapor bubbles (Figure 17-C) are formed when the piston's impact causes the liner walls to vibrate, sending pressure waves into the coolant.
3. These tiny vapor bubbles collect on the surface of metal parts. As the bubbles collapse (pop) a
microscopic piece of metal is eroded from the metal part. Over a period of time, this pitting may
progress completely through the cylinder liner of a wet-sleeve, heavy-duty diesel engine. This allows coolant to enter the combustion chamber. Engine failure or other serious damage will result.
A - Cylinder Liner Walls B - Engine Coolant C - Vapor Bubbles
Figure 17.
4. Unprotected engines with low quality water as cool-ant can have liner failure in as few as 500 hours.
WATER QUALITY1. Distilled, deionized, soft water is preferred for use in
cooling systems. Bottled distilled water from a food store or water supplier is recommended. Tap water often has a high mineral content. Tap water should NEVER be put in a cooling system unless fi rst tested by a water quality laboratory. Do not use water made by the reverse osmosis method unless it has been PH neutralized.
2. Here are acceptable water quality specifi cations:
Parts GrainsContaminates per Million per Gallon
Maximum Chlorides 40 2.5
Maximum Sulfates 100 5.9
Maximum Dissolved Solids 340 20.0
Maximum Total Hardness 170 10.0
PH Level 5.5 to 9.0
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Servicing
OMP 06-02
3. If chlorides, sulfates or total dissolved solids are higher than the above given specifi cation, the water must be distilled, demineralized, or deionized before it is used in a cooling system.
4. If total hardness is higher than 170 ppm and all other parameters are within the given specifi cations, the water must be softened before it is used to make coolant solution.
EGC: ETHYLENE GLYCOL CONCENTRATE(ANTIFREEZE)
CAUTION: EGC (Antifreeze) is fl ammable. Keep it away from any open fl ame. Avoid contact with eyes. Avoid contact with skin. Do not take inter-nally. In case of contact, immediately wash skin with soap and water. For eyes, fl ush with large amounts of water for at least 15 minutes. Call a physician. KEEP OUT OF REACH OF CHILDREN. Follow all warnings on the container.
1. Ethylene glycol coolant concentrate is commonly mixed with water to produce an engine coolant with a low freeze point and high boiling point.
2. A low silicate form of ethylene glycol coolant is recommended for all diesel engines.
3. Use an ethylene glycol coolant concentrate meeting ASTM D 4985P, SAEJ1941, General
Motors Performance Specifi cation GM1899M, or formulated to GM6038M.4. This product is concentrated and should be mixed to the following specifi cation.5. If additional coolant solution needs to be added to the engine due to leaks or loss, the glycol concentration should be checked with a hydrometer
to assure that the desired freeze point is maintained.
IMPORTANT1. DO NOT use methyl alcohol or methoxy propanol
base EGC. These concentrates are not compatible with chemicals used in supplemental coolant
additives. Damage can occur to rubber seals on cylinder liners which are in contact with coolant.2. DO NOT use an EGC containing sealer or stop-leak
additives.3. DO NOT use EGC containing more than 0.1%
anhydrous metasilicate. This type of concentrate, which is intended for use in aluminum engines, may cause a gel-like deposit to form that reduces heat transfer and coolant fl ow. Check container label or consult with supplier.
SUPPLEMENTAL COOLANT ADDITIVE (SCA)
CAUTION: Supplemental coolant additive contains alkali. Avoid contact with eyes. Avoid contact with skin. Do not take internally. In case of contact immediately wash skin with soap and water. For eyes, fl ush with large amounts of water for at least 15 minutes. Call a physician. KEEP OUT OF REACH OF CHILDREN. Follow all warnings on the container.
1. Important heat exchanger cooled engines Additional SCA's should NOT be added to the mixture of EGC/H20 on initial fi ll up of engines with a coolant conditioner-fi lter. A high SCA concentration will result and can cause silicate-dropout. When this happens, a gel-type
deposit is created in the cooling system which retards heat transfer and coolant fl ow.
2. If additional SCA's are needed, prepare a mixture of 50% quality water and 50%EGC (antifreeze). Add liquid SCA at a rate of 3%, by volume. Example: 30 mL of SCA per liter of H2O/EGC mixture (1.0 fl oz of SCA per qt of H2O/EGC). Add the resulting mixture to the cooling system in
quart increments. Run the engine for 2 hours and retest the coolant. Continue process until SCA
concentration meets recommended levels. 3. SCA is available from your Northern Lights dealer
in the following sizes. Pint - Part Number...............20-00002 1/2 gallon - Part Number.....20-000034. DO NOT use any coolant system additives containing soluble oil.
Distilled EGC % Freeze Boiling Water % Antifreeze Point Point
Optimum 50% 50% -37°C +109°C -34°F +226°F
Minimum 60% 40% -24°C +106°C -12°F +222°F
Maximum 40% 60% -52°C +111°C -62°F +232°F
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Servicing
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COOLANT TESTING1. Coolant test kits are available to allow on-site evalu-
ation of the coolant condition.2. The kits use small strips of paper which are dipped
into the coolant. The paper changes color and indi-cates the SCA concentration. It also indicates the amount of EGC (antifreeze).
3. Test kits are available through your Northern Lights or Lugger Dealer.
4 Pack - Part Number.......................20-00005 50 Pack - Part Number.....................20-00010
SP14. CHECKING COOLANT LEVEL.
CAUTION: The cooling water in the engine reaches extremely high temperatures. You must use extreme caution when working on hot engines to avoid burns. Allow the engine to cool before work-ing on the cooling system. Open the fi ller cap carefully, using protective clothing when the engine is warm.
1. Check the coolant level each day before starting the engine.
2. Remove the pressure cap from the expansion tank and check water level. In order to give the coolant
an opportunity to expand, the level should be about 1 3/4 in. (4-5 cm) below the fi ller cap sealing surface
when the engine is cold. When fi lling with cool-ant, the venting cock on top of the turbocharger (for engines fi tted with turbocharger) should be opened to ensure that no air pockets form in the cooling system.
2. The pressure valve in the fi ller cap releases when the pressure is approximately 7 PSI (0.5 bar). Use a cap pressure tester to check cap if you suspect it is faulty.
4. The makeup coolant, added to compensate for loss or leaks, must meet engine coolant requirements outlined in previous section.
SP15. FLUSHING THE COOLING SYSTEM
CAUTION: The cooling water in the engine reaches extremely high temperatures. You must use extreme caution when working on hot engines to avoid burns. Allow the engine to cool before working on the cooling system. Open the fi ller cap carefully, using protective clothing when the engine is warm.
1. Flush the cooling system and check for leaks and blockage every 600 hours, or yearly. The engine must be stopped and cold.
2. Close the seacock. 3. Remove the pressure cap from the expansion tank
with caution. If applicable, open the cooling system air vent on top of turbocharger.
4. Open the drains on the exhaust manifold and engine block. Drain the fresh water system (see Component Locations, pages 4 - 6).
5. For vessels with keel cooling, the vessel must be out of the water to allow draining of the keel cooler.
6. With drains open, pour clean water into the expansion tank. When the water from drain is clear and free from discoloration and sediment, close that drain. When all drains are closed, fl ushing is complete.
7. Fill the fresh water system by pouring the recommended coolant mixture as described in previ-
ous sections.8. Close cooling system air vent on turbocharger.9. Open the seacock.10. Start the engine. Check hoses and connections and
repair any leakage.
SP16. HEAT EXCHANGER CLEANING
1. Drain the cooling system.2. Remove the cooling water pipes between the heat
exchanger and the water pump inlet.3. Disconnect hose to seawater pump.4. Unscrew the attaching bolts holding the heat
exchanger to the expansion tank.5. Remove bolts holding heat exchanger cover.6. Wash the core inside and out. If necessary, chemical
agents can be used. Also clean the accessible parts of the heat exchanger housing.
7. Reassemble, using new gaskets and sealing rings; see page 28 for assembly drawing.
SP18. ZINC ANODES
1. Zincs are installed in the cooling system to protect your engine from electrolysis. Check them faithfully every 250 hours. If you are in warm salt water or where electrolysis is a known problem, check them more often.
22
Servicing
OMP 06-02
Heat exchanger cooled engine:
a. Drain the raw water from heat exchanger (see Component Locations). b. Remove zinc holders from back of the tank and from front and port side of the heat exchanger (see Component Locations).
Keel Cooled engines.
a. Drain expansion tank and remove zinc holder from tank (see Component Locations).
2. Scrape or steel brush the zinc electrode clean. If more than 50% of the electrode has eroded away, replace it with a new one. The electrode screws out of the holder.
3. Reinstall the zinc holders. Be sure the threads are clean and have good metal to metal contact.
SP19. RAW WATER PUMP
Heat exchanged cooled engines only.
1. Change the sea water pump impeller as needed.2. Remove the pump end cover. Remove impeller with
water pump pliers. Be sure you remove all pieces of a failed impeller.
3. Clean the inside of the housing.4. Press in the new impeller and place the sealing
washer in the outer end of the impeller center if this has not already been done.
5. Replace the cover using a new gasket.
Note: Make sure there is always an extra impeller and cover gasket in reserve and on-board.
SP20, 21. DRIVEN EQUIPMENT
Gears and PTO's
1. Manufacturer's service recommendations vary. See your Owner's Manual for service information. If you do not have a manual, see your local dealer for the equipment in question.
NOTE: Some PTO and marine gears have rigid lubrication requirements. Follow service recommendations closely.
Generator Ends
2. The maintenance and operation recommendations for the generator end are in a separate Owner's Manual. If you do not have one of these manuals, contact your local Northern Lights dealer.
ELECTRICAL SYSTEM - GENERAL
1. Never switch battery switch off or break the circuit between the alternator and batteries while the engine is running. Regulator damage can result.
2. DO NOT reverse the polarity of battery cables when installing the battery.
3. When welding on the unit, disconnect the regulator and battery. Isolate the leads.
4. Disconnect battery cables when servicing the DC alternator.
5. Never test with a screwdriver, etc., against any terminal to see if it emits sparks.6. A DC circuit breaker protects your control panel and
wiring harness.
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Servicing
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BOOSTER BATTERIES
CAUTION: Battery Gas Can Explode. Keep all fl ames and sparks away from batteries.
1. Before changing or using booster batteries, check battery electrolyte level. Add distilled water.
2. Booster and main batteries must have the same voltage rating.3. First, connect positive (+) terminal of booster battery to positive (+) terminal of main battery.
Figure 18: Booster Battery Connections
4. Then, connect negative (-) terminal of booster battery to ground on the engine block (see Figure 18).
5. Remove booster battery after starting engine.6. Sealed batteries: see manufacturer charging and
booster instructions.
SP16-17. BATTERY CARE - LEAD/ACID TYPE BATTERIES
1. Check electrolyte level every 50 hours or once per month. Add distilled water to manufacturer's recommended level.2. Batteries, cables and cable terminals should be
checked and cleaned every 100 hours. Clean corrosion with a water and baking soda solution.
Flush with clean water. Tighten terminals and grease them to inhibit corrosion.3. Check the battery condition with a hydrometer every 750 hours.
SP27. WINTERIZING, OUT-OF-SERVICE
1. Drain seawater cooling systems completely. Remember to shut off sea cocks before opening
drain cocks.2. Drain seawater supply lines and wet exhaust line.3. Loosen the seawater pump cover and drain pump.4. Check freshwater antifreeze mixture. If refi lling, use
the proper mix of coolant.
24
Servicing
OMP 06-02
If you cannot correct problems with these procedures, see your Lugger or Northern Lights dealer.
Low battery output: • Check electrolyte level and condition. Excessive resistance in starting circuit: • Clean and tighten all battery connections. Crankcase oil too heavy: • Use oil of proper viscosity. Improper type of fuel: • Consult fuel supplier and use proper type of fuel for operating condition. Water, dirt or air in fuel system: • Drain, fl ush, fi ll and bleed system. Clogged primary fuel fi lter element: • Clean or replace fi lter element. Clogged secondary fuel fi lter element: • Replace fi lter element. Dirty or faulty injection nozzles: • Have your dealer check injection nozzles. Engine Runs Irregularly or Stalls Frequently Below normal engine temperature: • Remove and check thermostat. Clogged primary fuel fi lter element: • Clean or replace fi lter element. Clogged secondary fuel fi lter element: • Replace secondary fi lter element. Water or dirt in the fuel system: • Drain, fl ush, fi ll and bleed system. Dirty or faulty injection nozzles: • Have your dealer check injection nozzles. Air in fuel system: • Inspect clamps and hoses on suction side of fuel pump for air leak, bleed fuel system. Improper type of fuel: • Consult fuel supplier and use proper type of fuel for operating condition. Lack of Engine Power Intake air restriction: • Service air cleaner. Clogged primary fuel fi lter element: • Clean or replace fi lter element. Clogged secondary fuel fi lter element: • Replace fi lter element. Lack of Engine Power (continued) Improper type of fuel: • Consult fuel supplier and use proper type of fuel for operating conditions. Overheated engine: • See “Engine Overheats” in next category. Below normal engine temperature: • Remove and check thermostat.
25
DC ELECTRICAL SYSTEM Battery Will Not Charge Loose or corroded connections: • Clean and tighten battery connections. Sulfated or worn out batteries: • Check specifi c gravity of each battery cell. • Check electrolyte level of each battery cell. Loose or defective alternator belt: • Adjust belt tension. • Replace belt. Starter Inoperative Check DC circuit breaker: • If the breaker is tripped, reset it. Loose or corroded connections: • Clean and tighten loose battery and harness plug connection. Low battery output: • Check specifi c gravity of each battery cell. • Check electrolyte level of each battery cell. Defective electrical system ground wire: • Repair or replace. Starter Cranks Slowly Low battery output: • Battery is too small. • Battery cables are too small. Check specifi c gravity of each battery cell: • Replace battery if necessary. Check electrolyte level of each battery cell: • If low, fi ll cells with distilled water. Crankcase oil too heavy: • Fill with oil of appropriate viscosity. Loose or corroded connections: • Clean and tighten loose connections. Entire Electrical System Does Not Function Check DC circuit breaker: • If breaker is tripped, reset it. Faulty connection: • Clean and tighten battery and harness plug connections. Sulfated or worn out batteries: • Check specifi c gravity and electrolyte level of each battery cell.ENGINE Engine Hard to Start or Will Not Start Improper starting procedure: • See starting section of this manual. Take special note of Bypass Switch operation. No fuel: • Check level of fuel in fuel tank.
Troubleshooting
OMP 06-02
If you cannot correct problems with these procedures, see your Lugger or Northern Lights dealer.
Below Normal Engine Temperature Thermostats not working properly: • Check thermostats. Temperature gauge not working properly: • Check water temperature with thermometer. Low Oil Pressure Low oil level: • Fill crankcase to proper level. Improper type of oil: • Drain and fi ll crankcase with correct oil. Partially plugged oil fi lter: • Replace fi lter. High Oil Consumption Break-in period: • Oil consumption decreases after break in. Crankcase oil too light: • Use proper viscosity oil. Oil leaks: • Check for leaks in lines around gaskets and drain plug. Engine Emits Black or Gray Exhaust Smoke Clogged or dirty air cleaner: • Service air cleaner. Defective muffl er (back pressure too high): • Have dealer check back pressure. Improper fuel: • Use correct fuel for temperature. Injection nozzles dirty: • See your dealer. Engine out of time: • See your dealer. Engine Emits White Smoke Improper fuel: • Use correct fuel for temperature. Cold engine: • Warm up engine to normal operating temperature. Defective thermostat: • Remove and check thermostat. Engine out of time: • See your dealer.
26
Improper valve clearance: • Reset valves. Best done by dealer. Dirty or faulty injection nozzles: • Replace injectors. Best done by dealer. • See your local dealer. Engine Overheats Low coolant level: • Fill tank or radiator to proper level. • Check hoses for loose connections and leaks. Keel cooling tubes have been painted (marine): • Remove paint from tubes. Cooling system needs fl ushing: • Flush cooling system. Defective thermostat: • Remove and check thermostat. Defective temperature gauge: • Check water temperature with thermometer and replace gauge if necessary. Water pump impeller worn/broken: • Check impeller and replace if necessary. Engine Knocks Insuffi cient oil: • Call your dealer. Injection pump out of time: • Call your dealer. Below normal engine temperature: • Check your thermostats. • Check water temperature to see if temperature gauge is working properly. Engine overheating: • See “Engine Overheating” section. High Fuel Consumption Air in fuel system: • Bleed fuel system. Improper type of fuel: • Use correct fuel for temperature. Clogged or dirty air cleaner: • Service air cleaner. Improper valve clearance: • See your dealer. Injection nozzles dirty: • See your dealer. Injection pump out of time: • See your dealer. Engine not at proper temperature: • Check your thermostats. • Check water temperature with thermometer and replace gauge if necessary.
Troubleshooting
OMP 06-02
1800 and 1500 RPM GENERATOR SETS
Model Number MP445D MP445T MP445H MP668T MP668H
AC Output 1
1800 RPM, 60 Hz 40 kW 55 kW 65 kW 80 kW 99kW 1500 RPM, 50 Hz 33 kW 45 kW 55 kW 66 kW 80kWPhase All Models - Available in Single or Three Phase OutputRPM / Hz All Models - Available in 1800 RPM/60 Hz and 1500 RPM/ 50 Hz Voltages / 60 Hz All Models / 60 Hz - 120/208, 120/240, 127/220, 139/240, 219/380, 240/416, 254/440, and 277/480 Voltages / 50 Hz All Models / 50 Hz - 110/190, 110/220, 115/230, 120/208, 127/220, 220/380, and 240/416
EngineAspiration Natural Turbo Turbo Turbo TurboCylinders Inline 4 Inline 4 Inline 4 Inline 6 Inline 6Displacement 276 cu in 276 cu in 276 cu in 414 cu in 414 cu in (4.5 l ) (4.5 l) (4.5 l ) (6.8 l ) (6.8 l)Bore 4.2 in 4.2 in 4.2 in 4.2 in 4.2 in (106 mm) (106 mm) (106 mm) (106 mm) (106 mm)Stroke 5.0 in 5.0 in 5.0 in 5.0 in 5.0 in (127 mm) (127 mm) (127 mm) (127 mm) (127 mm)HP at 1800 RPM 2 67 83 93 120 149Specifi c Fuel Rate 3 0.367 lb/bhp/hr 0.35 lb/bhp/hr 0.36 lb/bhp/hr 0.343 lb/bhp/hr 0.345 lb/bhp/hrApprox. Fuel Rate 4 3.3 gph 4.4 gph 4.7 gph 6.53 gph 7.28 gph (12.5 l ph) (16.7 l ph) (17.8 l ph) (24.7 l ph) (27.6 l ph)
Dimensional Data 5
Length 64 in 68 in 71 in 81 in 86 in (1630 mm) (1730 mm) (1800 mm) (2060 mm) (2180 mm)Width 30 in 30 in 30 in 30 in 30 in (762 mm) (762 mm) (762 mm) (762 mm) (762 mm)Height 40.2 in 40.2 in 40.2 in 40.2 in 40.2 in (1021 mm) (1021 mm) (1021 mm) (1021 mm) (1021 mm)Approximate Weight 1865 lbs 1920 lbs 2150 lbs 2720 lbs 2930 lbs (846 kg) (871 kg) (975 kg) (1230 kg) (1330 kg)
1200 RPM GENERATOR SETS
Model Number MP668QT
AC Output 1
1200 RPM, 60 Hz 50 kW Phase All Models - Available in single or three phase Voltages / 60 Hz All Models / 60 Hz - 120/208, 120/240, 127/220, 139/240, 220/380, 240/416, 254/440, and 277/480
EngineAspiration Turbo Cylinders Inline 6 Displacement 414 cu in (6.8 l) Bore 4.2 in (106 mm) Stroke 5.0 in (127 mm) HP at 1200 RPM 2 75 Specifi c Fuel Rate 3 0.353 lb/bhp/hr Approx. Fuel Rate 4 3.63 gph (13.8 l ph)
Dimensional Data 5
Length 81.44 in (2070 mm) Width 30 in (762 mm) Height 40.2 in (1021 mm) Approximate Weight 3 0 2635 lbs (1200 kg)
1. Prime kW rating. 1 kW equals 1000 watts. 0.8 power factor.2. Net fl ywheel hp rating for fully equipped engine at 1800 (1200) RPM under SAE J816b. 3. Based on prime HP rating at 1800 (1200) RPM.4. Based on prime kW rating at 1800 (1200) RPM. Fuel rate may vary depending on operating conditions.5. Installation data for units with standard mounts, heat exchanger cooling, 1800 RPM, and 3 phase generator ends. Dimensions and weight are effected by optional equipment, AC output and cooling confi guration. Contact factory for more information.
27
Specifi cations
OMP 06-02
28
Heat Exchanger
Description and Part Numbers
1. Heat Exchanger, 20-19501 10. Hex nut, 14-003222. Gasket, 11-11043 11. Hose, 18-625203. O-ring, 16-19502 12. Hose clamp, 19-010284. Capscrew, 12-00312 13. Tube, 27-110355. Capscrew, 12-00354 14. Plug, 21-005306. Lock washer, 15-00302 15. O-ring, 16-148047. Stud, 13-00335 16. Capscrew, 12-007138. Snubbing washer, 15-70007 17. Lock washer, 15-007029. Neoprene washer, 15-19504
Heat Exchanger Kit LP-MP445/668 Drawing C-4143
OMP 06-02
29
Wiring Diagrams
D.C
. Wiri
ng -
MP
445/
668
12V
DC
E
ngin
e an
d C
ontro
l Pan
el
D
raw
ing
C-4
222
OMP 06-02
30
Wiring Diagrams
D.C
. Wiri
ng -
MP
445/
668
12V
DC
Iso
late
d G
roun
d
Eng
ine
and
Con
trol P
anel
Dra
win
g C
-422
3C
OMP 06-02
31
Wiring Diagrams
D.C
. Wiri
ng -
MP
445/
668
24V
DC
E
ngin
e an
d C
ontro
l Pan
el
D
raw
ing
C-4
224A
OMP 06-02
32
Wiring Diagrams
D.C
. Wiri
ng -
MP
445/
668
24 V
DC
Iso
late
d G
roun
d
Dra
win
g C
-422
5B
OMP 06-02
33
On Board Spare Parts
World Item Description Standard Class
1 Lube Oil Filter 4 4
2 Air Filter Element 1 1
3 Fuel Filter 2 2
4 Injector 0 6
5 Thermostat 2 2
6 Thermostat Ring 2 2
7 Relay 0 2
8 Valve Cover Gasket 1 2
9 Gasket Kit Top 0 1
10 Gasket Kit Bottom 0 1
11 Zinc* 6 12
12 Raw Water Pump Impeller* 2 2
13 Raw Water Pump Cover Gasket* 2 2
14 Raw Water Pump* 0 1
15 Workshop Manual 0 1
16 Set of Alternator Belts 1 1
17 Fuel Washer Kit Std.1 w/c 1
*Heat exchanger cooled engines only
Safety at sea depends on careful preparation, product knowledge, and having the right tools and parts. Below is a list of parts Alaska Diesel Electric, Inc. recommends you carry onboard at all times.
Onboard Parts Kits are available from your dealer. “Standard” Kits are suitable for inland and offshore cruising. “World Class” Kits are for world cruising and trans-ocean cruising.
We consider these minimum quantities. Your vessel's operating conditions may require more of a given part. Consult your dealer.
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